up front flow assurance(looping)otc2010

8/12/2019 Up Front Flow Assurance(Looping)OTC2010

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www.cd-adapco.com

Flow Assurance By DesignMulti-Fidelity Simulation for

Improved Design, Development, and Validationof Subsea Pipelines and Equipment



What You Need to Know…

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The importance of “Up-Front” and

“Multi-Fidelity” simulation

The Company Behind the Solutions:CD-adapco

Examples and Benefits of 3-D Flow andThermal Simulation

The Software Behind the Benefits:STAR-CCM



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Ocean Temperature

Ocean Pressure

Well Fluid Temp/pressure

Slugging/Hydrates

Inhibitors

Accessibility for Repair/Replacement



The Importance of 3D Simulation in Engineering Design

• “The deeper you go, the less you know”

– Engineers need to know if proposed equipment and systemdesigns will function properly under increasingly harshoperating offshore/subsea conditions

– Past experience and “gut feel” become less reliable in newand unfamiliar environments

– Physical testing of components/equipment is increasinglyexpensive and less reliable due to scaling assumptions

• 3D Simulation is rapidly moving from a troubleshooting tool

into a leading position as a design tool: “ Up-Front”numerical/virtual testing to validate and improve designsbefore they are built and installed



The Importance of Using the Right Numerical Tools

• To be effective, simulations must be

– Fast enough to provide answers within the design timeframe

– Accurate enough to provide sufficiently insightful answers forbetter design decisions

• Choice and use of a judicious mix of tools for Multi-FidelitySimulation to meet these effectiveness requirements, e.g.

– 1-D simulations (e.g., OLGA) for long pipeline systems

– 3-D simulations (STAR-CCM+) for 3D equipment, transitionregions

– A user-friendly computing environment for activating the rightmix of tools for the situation being examined: co-simulation



Flow Assurance Toolkit: 1D, 3D & Test

• 1D codes such as OLGA: – Fast, for overall networks & long pipelines

– But…limits to physics/geometry, tuned from empiricism

• Test:

– Includes all physics

– Costly, time-consuming, lack of facility availability, scaling, dataacquisition

• 3D CFD with STAR-CCM+ / coupled 1D-3D:

– Higher fidelity physics/geometry – Detailed simulation

– More computing resource required (but getting cheaper)

It’s cheaper to be wrong in the virtual world--

Failure in the real world is not an option



Example Areas for Use of 3D Flow and Thermal

Simulation in Deep Offshore Engineering

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ICV/Valves

Jumpers/errosion

Sand transport Coldspots

Split nodes Pumps

Advanced thermal /flow modeling

Subsea processing

Component Errosion

Subsea and topside:

Separators/Slugcatchers/FWKO

VIV of risers/umbilicals

Drill Bits/Sand Control



Further Relevant Topside 3D Flow and Thermal

Simulation Application Areas

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Tankers/LNG Ships: Seakeeping, Sloshing, Propulsion

Offshore Platforms: Wave Slamming, Wind Loading

VIM of Spars

Flare Combustion/Radiation



Subsea Applications (partial list)

• Gas lift

• Equipment sizing

• Operating procedures

• Cool-down times/insulation

• Solid transport

• Displacement problems

• Hydrate remediation• Testing of assumptions

(e.g. wax during pigging)

• VIV

• Heat transfer coefficinets

• In-pipe heating

• Installation (componentloads)

• Equipment optimization (weightreduction)

• Erosion

• Heavy oils• Inhibitors, top-line wetting

• Sulfur transport/melting



Troubleshooting with 3D Simulation

• Deeper insight into operation of

existing equipment

• Greater spatial/temporal resolution

• Confidence that you’ll

get it right the first time!

• Failure is not an option

• Example: pipeline VIV



Carryover in Separator:Dynamic Free-Surface Tracking



Riser section of long pipeline: 3D CFD Captures

Transition of Flow Regimes Around Sharp Bends



Effects of Cooling in Transportation of Viscous Oil

• When heavy/viscous oil is cooled along the pipe, expectdensity and viscosity to increase as temperature drops.

• 3D simulation is used to capture the cross-sectional effects.



Pressure drop along pipe

With cooling

Isothermal



Multiphase Flow in Pipe Bends

Large bubbles

Mediumbubbles

Small bubbles

Liquid

4-phase model for

more accuracy

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Example: Riser Section



• Identify possible occurrence and location of cold spots in open loop

electrically-heated sub-sea pipeline.

• Identify three-dimensional heat transfer effects important during the

pipeline cool down.

• Sub-sea pipeline –wellhead to platform

• Sections are electrically heated and unheated – e.g., riser unheated.

Example: Thermal Study (1)

Blue – unprotected pipeline section

Red – heated pipeline sectionOrange – riser (unheated)



• Initial start-up oil, water & gas pumped into the pipeline until anapproximate steady-state condition is reached (Duration: 2 hrs).

• Shutdown fluids within the pipeline are allowed to settle and

redistribute (Duration: 1hr).

• Cool down fluid in pipeline allowed to cool down. Electrical heating

is activated when the fluid temperature in the pipeline reaches 25oC.

(Duration: 36 hrs)

• Start-up oil, water & gas pumped into the pipeline until an

approximate steady-state condition is reached (Duration: 2 hrs).




Examples: Solid Transport / Erosion



Examples: Solid Transport / Erosion

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“These applications demonstrate that CFD offers the potential for huge

advancements in drilling, especially under more challenging conditions. CFD

gives design engineers the ability to easily and accurately analyze fluid flow,

making it possible to rapidly evaluate alternatives and also provides

comprehensive diagnostic information. The result is that design engineers

can optimize the drilling bit from a fluid flow perspective during the design

phase.”

--Dr. Michael Wells Director of Research and Development

Hughes Christensen Division of Baker Hughes

The optimized case (right) has 67% less erosion than the original case (left) The optimized case (right) has 67% less erosion than the original case (left) The optimized case (right) has 67% less erosion than the original case (left)

The optimized case (right) has 67% less erosion than the original case (left)

The optimized case (right) has 67% less erosion than the original case (left) The optimized case (right) has 67% less erosion than the original case (left) The optimized case (right) has 67% less erosion than the original case (left)

Testimonial to the Benefits of 3D CFD

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The Software Behind the Benefits:

STAR-CCM



The Integrated Flow, Thermal and Stress Process

Geometry Import &CAD –EmbeddedFront End

AcceleratedPre-Processingwith SurfaceWrapping

AutomatedVolumeMeshing

AdvancedPhysicsSolutions



Your CAE Partner for Success 26

Pipe Junction: flow regime disruption

2m

Some Further Examples of

3D Flow/Thermal Simulation Solutions…

Slug Catcher

Christmas Tree:

Bubble Simulation

Pig Insertion

Top-side Separator



• The world’s largest independent flow/thermal-focused provider of 3D transient engineering simulation solutions (CFD)

– software, consulting (20% of turnover), mentoring, training

– STAR-CCM+ : the world’s best 3D simulation environment

• ~30 years of providing flow, thermal, and stress solutions across industries

from oil & gas, nuclear, chemical, automotive, to aerospace & defense• Independence allows flexibility in meeting engineering challenges

• Over US$100 million p.a. end-user spend, 17-20% current growth rate

• 450+ employees across 21 offices in 8 countries

– 90% postgraduate degrees; 40% PhDs

• More than 8000 users in over 3500 companies• Multiphase process equipment CFD knowhow:

• Individuals who have help shape today’s CFD world:» Prof. Gosman, Prof. Lo, Prof. Peric

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CD-adapco: The Company Behind the Solutions



A Selection of our Oil and Gas Clients



• CD-adapco and SPT established a partnership in 2008 to develop/integrate tools for Up-Front (Multi-Fidelity) Computational Flow Assurance. Both companies are fully committed.

• Very close working relationship between management and engineers.

• To develop and enhance the

STAR-OLGA Link : CD-adapcoengineers from New York andLondon offices visit &work withSPT experts in SPT Osloheadquarters.

• CD-adapco and SPT arepartners in European TMF andFACE research consortia, US(U. Of Tulsa) Hydrates JIP.



OLGA-STAR Coupling for Co-Simulation:

The Concept

OLGA <-> STAR:

Flow rates/pressure

STAR <-> OLGA:

Flow rates/pressure

Study 3D effects of in-line equipment: valves, junctions, elbows, risers, obstacles, jumpers,separators, slug catchers, compressors, ...

One-way or two-way, one end or multiple ends of 3D in-line equipment



OLGA-STAR Link Example:

Slugcatcher Investigation

• Slugcatcher undersized?• Original design with 5 tanks

• Built with only two (cost saving)

• Questions:

• what happens during pigging?

• carryover?• hydrate/wax particles melt?

• Gas/oil/water flow: co-simulation withOLGA for upstream pipeline input



SLUG CATCHER (Upstream Olga Model)

(24 Km)

(200m)



SLUG CATCHER: Oil Surface

Olga Oil Flow Rate Bluegraph below

(BC to CFD Model)



Jumper Experimental Setup

(U. of Tulsa Hydrates JIP: scale)



Talk to Us About Next Steps…

• More detailed technical presentations on specifictopics/examples of interest (live or via Webex)

• STAR-CCM+ demonstration (live or Webex)

• Trial licenses, Training, Mentoring

• Benchmarks/pilot project(s)



Come to CD-adapco’s 2nd Annual

STAR Global Forum 2 1 : Simulation for Energy Engineering

Professor Philip J. Smith, Director Institute for Clean and Secure Energy (ICSE)

University of Utah

A. Michael Schaal, DirectorOil and Gas Division

Office of Integrated Analysis and ForecastingEnergy Information Administration (DOE)

up front flow assurance(looping)otc2010

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